Grundfos KPL.700-1400 Operating instructions

Oil service kit

KPL.700-1400, KWM.700-1400

Service instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Service instructions

Original service instructions.

CONTENTS

Page

1. General information

These service instructions describe how to change oil in KPL

axial-flow propeller pumps and KWM mixed-flow impeller pumps

installed in column pipes with diameters from DN 700 to 1400.

For instructions on how to change oil in KPL and KWM pumps

with column pipe diameters from DN 500 to 650 or for more

general service instructions, see the KPL, KWM service

instructions, product number 98383809, available in the Grundfos

Product Center on Grundfos' homepage, www.grundfos.com.

1.1 Symbols used in this document

2. Safety

1. General information 2

1.1 Symbols used in this document 2

2. Safety 2

3. Oil service kit, KPL.700-800 and KWM.700-800 3

3.1 Assembling the oil pipe 3

3.2 Draining the oil 5

3.3 Filling oil 6

3.4 Checking the oil level 7

4. Oil service kit, KPL.900-1400 and KWM.900-1400 9

4.1 Assembling the oil pipe 9

4.2 Draining the oil 10

4.3 Filling oil 11

4.4 Checking the oil level 12

5. Oil quantity 12

5.1 Oil quantity according to column pipe diameter 12

Warning

If these safety instructions are not observed,

it may result in personal injury.

Warning

During electrical installation, make sure that the

power supply cannot be accidentally switched

on.

Warning

These instructions must be observed for

explosion-proof pumps. We recommend that you

also follow these instructions for standard

pumps.

Caution

If these safety instructions are not observed, it

may result in malfunction or damage to the

equipment.

Note

Notes or instructions that make the job easier

and ensure safe operation.

Warning

Make sure that the mains switch can be locked in

the 0/Off position. Type and requirements must

comply with EN 60204-1, 5.3.2.

Warning

Observe local regulations setting limits for

manual lifting or handling.

Warning

For safety reasons, all work in pump pits must be

supervised by a person outside the pit.

Warning

Pits for submersible wastewater pumps contain

wastewater potentially with toxic and/or

disease-causing substances.

Therefore, while working on the pump, wear

appropriate personal protective equipment and

clothing. In addition, carry out work on or near

the pump under strict observance of the hygiene

regulations in force.

English (GB)

3. Oil service kit, KPL.700-800 and KWM.700-800

3.1 Assembling the oil pipe

Fig. 1 Oil service kit, KPL.700-800 and KWM.700-800

Where nothing else is indicated, the position numbers refer to fig.

1and/or the figure below each step.

1. Connect the handle (pos. 24) to the rod (pos. 12).

2. Connect the intermediate pipe (pos. 10) to the barrel nipple

(pos. 16).

3. Connect the handle with rod (pos. A and step 1) to the

intermediate pipe with barrel nipple (pos. B and step 2).

4. Connect the handle with rod and the intermediate pipe with

barrel nipple (pos. C) to the intermediate pipe (pos. 11).

5. Connect the isolating valve (pos. 2) to the three-way tee fitting

(pos. 14).

6. Connect the isolating valve (pos. 17) to the barrel nipple (pos.

7).

7. Connect the isolating valve with barrel nipple (pos. F and step

6) to the isolating valve with three-way tee fitting (pos. E and

step 5).

TM06 3181 5014

Pos. Description

1Airhose

2 Isolating valve

3 Isolating valve

4 Intermediate fitting

5 Hexagon key

6 Hexagon key

7 Barrel nipple

8 Hexagon key

9 Barrel nipple

10 Intermediate pipe

11 Intermediate pipe

12 Rod

13 Funnel

14 Three-way tee fitting

15 Elbow fitting

16 Barrel nipple

17 Isolating valve

18 Handle

19 Plug

20 Intermediate fittings

21 Stub

22 Stub

23 Air pump

24 Handle

25 Air plug

TM06 3182 5014TM06 3183 5014TM06 3184 5014TM06 3185 5014TM06 3186 5014TM06 3187 5014TM06 3188 5014

24 12

10 16

214

17 7

English (GB)

8. Connect the handle with rod, the intermediate pipe with barrel

nipple and intermediate pipe (pos. D and step 4) to the

isolating valve with barrel nipple and three-way tee fitting

(pos. G and step 7).

9. Connect the plug (pos. 19).

The oil pipe is now completely assembled. See fig. 2.

Fig. 2 Assembled oil pipe, column pipe diameters DN

700-800

TM06 3189 5014TM06 3190 5014TM06 3191 5014

English (GB)

3.2 Draining the oil

Fig. 3 Sectional view, KPL.700-800 and KWM.700-800

1. Remove all the plugs (pos. 26, 27, 28 and 29).

Fig. 4 Draining oil, KPL.700-800, KWM.700-800

Where nothing else is indicated, the position numbers refer to fig.

4and/or the figure below each step.

2. Completely loosen the handle (pos. 24).

3. Close the isolating valves (pos. 17 and 31).

4. Insert the assembled oil pipe (pos. 35) in the lower oil plug

space (pos. 33).

5. Connect the intermediate fitting (fig. 1, pos. 20) to the air plug

(fig. 1, pos. 25).

6. Connect the stub (fig 1, pos. 21) to the intermediate fitting with

air plug (step 5). Fit the assembled component in the upper oil

plug space (pos. 32). See fig. 4.

7. Connect the stub (fig. 1, pos. 22) to the air pump (pos. 23).

8. Fit the air hose (pos. 1) between the air pump with stub (step

7) and the assembled stub, intermediate fitting and air plug

(step 6) fitted in the upper plug space (pos. 32).

9. Open the isolating valve (pos. 31).

10. Slowly tighten the handle (pos. 24) until the oil starts to flow.

11. Connect the air pump (pos. 23) to the power supply.

12. Drain the oil into an appropriate waste disposal container.

13. When the oil has been drained, disconnect the air pump (pos.

23) from the power supply.

14. Remove the assembled oil pipe (pos. 35) and the plug fitted in

the upper oil plug space (pos. 32).

TM06 3192 5014

Pos. Description

26 Upper casing plug

27 Lower casing plug

28 Upper oil plug

29 Lower oil plug

30 Non-return valve

TM06 3193 5014

Pos. Description

1Airhose

17 Isolating valve

23 Air pump

24 Handle

31 Isolating valve

32 Upper oil plug space

33 Lower oil plug space

34 Non-return valve

35 Assembled oil pipe

31 35

Waste

oil

TM06 3194 5014TM06 3195 5014TM06 3196 5014TM06 3197 5014

Note

Dispose of used oil in accordance with local

regulations.

2520

English (GB)

3.3 Filling oil

Fig. 5 Filling oil, KPL.700-800, KWM.700-800

Where nothing else is indicated, the position numbers refer to fig.

5and/or the figure below each step.

1. Disconnect the rod (fig. 1, pos. 12) from the handle (pos. 24).

2. Connect the handle (pos. 24) to the assembled oil pipe (pos.

35).

3. Disconnect the plug (fig. 1, pos. 19) from the four-way tee

fitting on the assembled oil pipe (pos. 35).

4. Connect the funnel (pos. 13) to the intermediate fitting (fig. 1,

pos. 4).

5. Connect the assembled funnel and fitting to the assembled oil

pipe (pos. 35).

6. Fit the assembled funnel, fitting and oil pipe (pos. 35) in the

upper casing plug space (pos. 36). See fig. 5.

7. Close the isolating valves (pos. 17 and 31).

8. Pour the recommended quantity of oil through the funnel (pos.

13). See section 5. Oil quantity.

9. After completing the oil filling, disconnect the assembled oil

pipe (pos. 35).

10. Refit the plugs (fig. 3, pos. 26 to 29).

TM06 3198 5014

Pos. Description

13 Funnel

17 Isolating valve

24 Handle

31 Isolating valve

32 Upper oil plug space

34 Non-return valve

35 Assembled oil pipe

36 Upper casing plug space

TM06 3199 5014TM06 3200 5014TM06 3201 5014

Oil

24 12

24 35

TM06 3202 5014TM06 3203 5014

Note

The non-return valve (pos. 34) prevents oil from

leaking.

Note

The air inside the oil chamber escapes through

the upper oil plug space (pos. 32) due to the

difference in diameter.

13 4

English (GB)

3.4 Checking the oil level

Fig. 6 Checking the oil level, KPL.700-800, KWM.700-800

Where nothing else is indicated, the position numbers refer to fig.

6and/or the figure below each step.

1. Connect the handle (pos. 24) to the rod (fig. 1, pos. 12).

2. Connect the handle (pos. 24) with rod (fig. 1, pos. 12) to the

assembled oil pipe (pos. 35).

3. Remove the funnel (fig. 1, pos. 13) with intermediate fitting

(fig. 1, pos. 4) from the assembled oil pipe (pos. 35).

4. Connect the plug (pos. 19) to the four-way tee fitting on the

assembled oil pipe (pos. 35).

TM06 3204 5014

Pos. Description

9 Intermediate fitting

15 Elbow fitting

17 Isolating valve

19 Plug

24 Handle

31 Isolating valve

33 Lower oil plug space

34 Non-return valve

35 Assembled oil pipe

37 Isolating valve

38 Sight glass

24 19 33

35 34

TM06 3205 5014TM06 3206 5014TM06 3207 5014TM06 3208 5014

24 12

English (GB)

5. Connect the elbow fitting (pos.15) to the intermediate fitting

(pos. 9).

6. Connect the sight glass (pos. 38) with isolating valve (fig. 1,

pos. 3) to the elbow fitting (pos. 15) with intermediate fitting

(pos. 9 and step 5).

7. Connect the sight glass (pos. 38) with isolating valve (fig. 1,

pos. 3) and fittings (pos. 15 and 9) to the isolating valve (pos.

17).

8. Completely loosen the handle (pos. 24).

9. Close the isolating valve (pos. 31). Fit the assembled oil pipe

(pos. 35) in the lower oil plug space (pos. 33). See fig. 6.

10. Open the isolating valves (pos. 17 and 37).

11. Slowly fasten the handle (pos. 24) until the oil level is visible

in the sight glass (pos. 38).

12. Wait until the oil level has stabilised.

13. Check the oil level marked "MIN" according to the pipe column

diameter. See fig. 6, detail A.

14. After the oil level check, loosen the handle (pos. 24) to close

the non-return valve (pos. 34).

15. Open the isolating valve (pos. 31), and drain the remaining oil

from the sight glass (pos. 38) into an appropriate waste

disposal container.

16. Disassemble the oil pipe and place it in the suitcase (fig. 1) for

storage.

17. Fit oil and casing plugs (fig. 3, pos. 26-29).

TM06 3209 5014TM06 3210 5014TM06 3211 5014

Note

Handle the sight glass (pos. 38) with care.

15 9

English (GB)

4. Oil service kit, KPL.900-1400 and

KWM.900-1400

4.1 Assembling the oil pipe

Fig. 7 Oil service kit, KPL.900-1400 and KWM.900-1400

Where nothing else is indicated, the position numbers refer to fig.

7and/or the figure below each step.

1. Connect the handle (pos. 18) to the rod (pos. 9).

2. Connect the intermediate pipe (pos. 8) to the oil pipe (pos.

12).

3. Connect the handle with rod (pos. A and step 1) to the

intermediate pipe with oil pipe (pos. B and step 2).

4. Connect the isolating valve (pos. 3) to the intermediate pipe

(pos. 10).

5. Connect the handle with rod and the intermediate pipe with oil

pipe (pos. C and step 3) to the assembled isolating valve and

intermediate pipe (pos. D and step 4).

6. Connect the plug (pos. 14) to the assembled handle, rod,

intermediate pipe, oil pipe, isolating valve and intermediate

pipe (pos. E and step 5).

The oil pipe is now completely assembled. See fig. 8.

Fig. 8 Assembled oil pipe, KPL.900-1400, KWM.900-1400

TM06 3212 5014

Pos. Description

1Airhose

2 Sight glass with fittings

3 Isolating valve

4 Hexagon key

5 Intermediate fitting

6 Hexagon key

7 Hexagon key

8 Intermediate pipe

9Rod

10 Intermediate pipe

11 Funnel

12 Oil pipe

13 Handle

14 Plug

15 Intermediate fitting

16 Stub

17 Stub

18 Handle

19 Air plug

20 Air pump

TM06 3213 5014TM06 3214 5014TM06 3215 5014TM06 3216 5014TM06 3217 5014TM06 3218 5014TM06 3219 5014

812

310

E14

English (GB)

4.2 Draining the oil

Fig. 9 Sectional view, KPL.900-1400 and KWM.900-1400

1. Remove all the plugs (pos. 21, 22, 23 and 24).

Fig. 10 Draining oil, KPL.900-1400, KWM.900-1400

Where nothing else is indicated, the position numbers refer to fig.

10 and/or the figure below each step.

2. Completely loosen the handle (pos. 18).

3. Close the isolating valve (pos. 26).

4. Insert the assembled oil pipe (pos. 27) in the lower oil plug

space (pos. 29).

5. Connect the intermediate fitting (fig. 7, pos. 15) to the air plug

(fig. 7, pos. 19).

6. Connect the stub (fig. 7, pos. 16) to the intermediate fitting

with air plug (step 5). Fit the assembled component in the

upper oil plug space (pos. 28). See fig. 10.

7. Connect the stub (fig. 7, pos. 17) to the air pump (pos. 20).

8. Fit the air hose (pos. 1) between the air pump with stub (step

7) and the assembled stub, intermediate fitting and air plug

(step 6), fitted in the upper oil plug space (pos. 28). See fig.

10.

9. Open the isolating valve (pos. 26).

10. Slowly tighten the handle (pos. 18) until the oil starts to flow.

Make sure that the non-return valve (pos. 25) has been

activated when resistance is met.

11. Connect the air pump (pos. 20) to the power supply.

12. Drain the oil into an appropriate waste disposal container.

13. When the oil has been drained, disconnect the air pump (pos.

20) from the power supply.

14. Remove the assembled oil pipe (pos. 27) and the plug fitted in

the upper oil plug space (pos. 28).

TM06 3220 5014

Pos. Description

21 Upper casing plug

22 Lower casing plug

23 Upper oil plug

24 Lower oil plug

25 Non-return valve

TM06 3221 5014

Pos. Description

1Airhose

18 Handle

20 Air pump

25 Non-return valve

26 Isolating valve

27 Assembled oil pipe

28 Upper oil plug space

29 Lower oil plug space

21 23

24 25

20 1

2927

Waste

oil

TM06 3222 5014TM06 3223 5014TM06 3224 5014TM06 3225 5014

1915

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